How to splice repair a TempZone™ heating cable using butt connectors

Today, we will perform a twin conductor TempZone repair using the components from the repair kit. This kit includes a six-inch piece of 3/8-inch adhesive-lined heat shrink tube, which can be sourced from various suppliers. It is essential to ensure that the heat shrink tube is adhesive-lined or dual-walled, as this will provide a better seal. You can find these tubes at Fastenal, and the part number is included in the instruction sheet that accompanies the kit. Additionally, the kit contains two insulated butt connectors that are also heat shrinkable and feature solder in the middle, which we will melt using a heat gun. We also have an uninsulated butt connector for connecting the grounds once the repair is complete.

To begin, we will examine the wires. According to the instruction sheet, the wires should be cut about an inch back from the damaged area. It is important to cut one wire shorter than the other to create an offset, which helps prevent the thickest parts from resting against each other. This offset allows for a better fit when the heat shrink tubing is applied. After cutting the wires back by an inch and making the necessary offset cuts, we can proceed with the repair. When making these cuts, ensure that they are consistent in length to guarantee a proper connection. Using a gauge can help maintain uniformity in the cuts.

Before attaching the connectors, we need to slide the adhesive-lined heat shrink tube over the wires. This step is crucial, as the tubing cannot be added after the connectors are in place. Once the heat shrink tube is positioned, we will align the wires and set the uninsulated butt connector aside for later use. Next, we will insert the wire into the insulated butt connector until we feel a mechanical stop, indicating it has reached the end. After that, we will crimp the connector securely to hold the wire in place. It is vital to use wire strippers that include a crimping feature, ensuring that the correct size is used for the connectors. For the pink connectors, we will use the outer crimping spot, which is designed for the appropriate gauge.

After crimping the first connection, we will pull on it to confirm that it is secure. Once satisfied with the first connection, we will proceed to the second wire. We will repeat the crimping process, ensuring that the wires are the correct length and aligned properly. Again, we will pull on the connection to verify its integrity. Following this, we will heat the connectors to melt the solder inside, which will create a strong bond between the wires. As the solder melts, it will flow and encapsulate the wires, providing both a mechanical and a soldered connection that will not come apart.

Once the solder has melted and cooled, we will observe that it turns opaque, indicating a solid bond. It is essential to keep the wires straight during this process to ensure a good connection. After allowing the first connection to cool, we will move on to the second butt connector, repeating the crimping and soldering process. Once both connections are secure, we will add the heat shrink tubing around the soldered areas. It is important to heat the tubing evenly from all sides to ensure it contracts uniformly and adheres well to the wires, providing a waterproof seal.

Finally, we will connect the grounds using the uninsulated butt connector. Since the voltage-carrying wires are now isolated from the ground, there is no risk of contact. After securing the ground connection, we will apply the final layer of heat shrink tubing over the repair. While the kit provides six inches of tubing, you may trim it down to fit your specific needs, ensuring that the repair area is adequately covered. It is crucial to achieve a tight seal, as the adhesive inside the tubing will enhance waterproofing. If necessary, additional sealants like RTV or liquid tape can be used to fill any gaps. Once everything is in place, we can review the completed repair and confirm that it is secure and ready for use.